Composite materials including incompatible polymers and / or other incompatible materials

Abstract

Composite materials, methods of making composite materials, and methods of using composite materials are described herein. The composite material includes an incompatible polymer and / or other incompatible materials. The composite material can be used for various industrial applications. A composite material includes a first component including a first material having a fluid permeable portion and a second component including a second material that is incompatible with the first material; the first component and the second component are coupled at an interface, the interface comprising the second material contained in the fluid permeable portion of the first material, and the interface forming a third component separating at least a portion of the first component from the second component.

Description

Technical Field

[0001] This application claims the benefit of priority to U.S. Provisional Application No. 63 / 539,841, filed September 22, 2023, the disclosure of which is incorporated herein by reference in its entirety.

[0002] This disclosure relates to composite materials, methods for preparing composite materials, and methods for using composite materials. Composite materials include incompatible polymers and / or other incompatible materials. Composite materials can be used in a variety of industrial applications. Background Technology

[0003] It is desirable to join incompatible polymers and / or other incompatible materials to obtain composite materials in which the incompatible polymers and / or other incompatible materials are firmly bonded to each other at the molecular level, thereby improving strength, adhesion, durability, and sealing properties in a variety of applications. Conventional techniques for such joining include various welding techniques. However, conventional welding techniques are insufficient for welding certain combinations of incompatible polymers and / or other incompatible materials. For example, perfluorinated sulfonic acid (PFSA) polymers cannot be welded to common polymers such as polyethylene, polyethersulfone, and polypropylene. Instead, undesirable adhesives must be used to join such incompatible polymer materials.

[0004] The limitations of conventional welding techniques are particularly evident in applications requiring elevated temperatures and / or pressures. For example, gaskets, including those made of polymer composites used in energy conversion devices, are exposed to high operating pressures and temperatures, leading to deformation, degradation, and failure of membranes, polymer composites, and other components exposed to harsh conditions.

[0005] Therefore, this application seeks to provide composite materials comprising incompatible polymers and / or other incompatible materials. Surprisingly, it has been found in this application that composite materials comprising incompatible polymers and / or other incompatible materials can be produced by bonding the incompatible polymers and / or other incompatible materials to an interface comprising one material contained in a fluid-permeable portion of another material.

[0006] This article describes composite materials, methods for preparing composite materials, and methods for using composite materials. Composite materials include incompatible polymers and / or other incompatible materials. Summary of the Invention

[0007] In one aspect, this document provides a composite material comprising: a first component including a first material having a fluid-permeable portion; and a second component including a second material incompatible with the first material; wherein the first component and the second component are joined at an interface including the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component separating at least a portion of the first component from the second component.

[0008] In another aspect, this document provides a method for preparing a composite material comprising: a first component comprising a first material having a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are joined at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component separating at least a portion of the first component from the second component, wherein the method comprises: (i) receiving a liquid component comprising the second material and a liquid carrier in the fluid-permeable portion of the first material; and (ii) curing the liquid component in the fluid-permeable portion of the first material.

[0009] On the other hand, this document provides a method of using a composite material comprising: a first component comprising a first material having a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are joined at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component separating at least a portion of the first component from the second component, wherein the method comprises: (i) using the composite material to join a first surface comprising the first material and a second surface comprising the second material.

[0010] In another aspect, this document provides a membrane electrode assembly (MEA) comprising: a membrane; at least one electrocatalyst layer disposed on one side of the membrane; at least one gas diffusion substrate in physical contact with the at least one electrocatalyst layer; and a composite material comprising: a first component comprising a first material having a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component separating at least a portion of the first component from the second component; wherein the composite material is coupled to a first surface comprising a material compatible with the first material and / or a second surface comprising a material compatible with the second material; and wherein the first surface and / or the second surface are each selected from the surface of the membrane, the surface of a gasket, the surface of a sealing gasket, the surface of the at least one electrocatalyst layer, the surface of the at least one gas diffusion substrate, and combinations thereof. Attached Figure Description

[0011] Figure 1A This is a diagram depicting an exemplary embodiment of a composite material according to the present disclosure.

[0012] Figure 1B This is a diagram depicting an exemplary embodiment of a composite material according to the present disclosure.

[0013] Figure 2 This is a diagram depicting an exemplary embodiment of a product according to this disclosure.

[0014] Figure 3 This is a diagram depicting an exemplary embodiment of a composite material according to the present disclosure.

[0015] Figure 4 This is a diagram depicting an exemplary embodiment of a cross-sectional view of a component according to this disclosure.

[0016] Figure 5 This is a diagram depicting an exemplary embodiment of a composite material according to the present disclosure.

[0017] Figure 6 This is a diagram depicting an exemplary embodiment of a product according to this disclosure.

[0018] Figure 7 This is a method flowchart depicting an exemplary embodiment of the method according to the present disclosure.

[0019] Figure 8 This is a method flowchart depicting an exemplary embodiment of the method according to the present disclosure.

[0020] Figure 9This is a diagram depicting an exemplary embodiment of a component according to this disclosure.

[0021] Figure 10 This is a diagram depicting an exemplary embodiment of a material including a fluid-permeable portion according to this disclosure. Detailed Implementation

[0022] This disclosure relates to composite materials, methods for preparing composite materials, and methods for using composite materials. Composite materials include incompatible polymers and / or other incompatible materials.

[0023] As used herein, incompatible polymers and / or other incompatible materials are chemically incompatible polymers and / or materials (e.g., due to differences in hydrophobicity or hydrophilicity), polymers and / or materials that cannot be fused together by thermal or welding techniques, immiscible polymers and / or materials, and / or polymers and / or materials that have different melt flow characteristics.

[0024] As used herein, compatible polymers or materials are chemically compatible polymers and / or other materials (e.g., due to similar hydrophobicity or hydrophilicity), polymers and / or other materials that can be fused together by thermal or welding techniques, miscible polymers and / or other materials, and / or polymers and / or materials that have similar melt flow properties.

[0025] In many embodiments, the composite material according to the present disclosure includes: a first component comprising a first material having a fluid-permeable portion; and a second component comprising a second material incompatible with the first material, wherein the first component and the second component are joined at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component separating at least a portion of the first component from the second component.

[0026] Figure 1A This is an exemplary diagram of composite material 110. In this exemplary embodiment, composite material 110 depicts an exemplary composite material and is not intended to limit the composition embodiments. In this exemplary embodiment, composite material 110 includes a first component 112, a second component 114, and an interface 116. The first component includes a first material having a fluid-permeable portion, and the second component includes a second material incompatible with the first material. Interface 116 includes the second material contained within the fluid-permeable portion of the first material. Although this exemplary embodiment depicts the first component 112, the second component 114, and the interface 116 as having certain dimensions and thicknesses, this depiction is not limiting.

[0027] Figure 1BThis is an exemplary diagram of composite material 110. In this exemplary embodiment, composite material 110 depicts an exemplary composite material and is not intended to limit the composition embodiments. In this exemplary embodiment, composite material 110 includes: a first layer, first component 112, the first component including a first material having a fluid-permeable portion; a second layer, first component 113, the first component including a third material that is the same as, similar to, or different from the first material, optionally including a fluid-permeable portion; a second component 114, the second component including a second material incompatible with the first material; and an interface 116. In this exemplary embodiment, the second material of the second component 114 penetrates the interface 116 and the first layer, first component 112, and optionally partially penetrates the second layer, first component 113. That is, the interface 116, the first component 112, and the optional first component 113 each include a second material contained in their fluid-permeable portions. Although the exemplary embodiment depicts the first component 112, first component 113, second component 114, and interface 116 as having certain dimensions and thicknesses, this depiction is not limiting.

[0028] Typically, the first material can be any suitable material known in the art that is advantageous to the composite material described herein. In some embodiments, the first material is selected from porous polymer materials, polyolefins, aromatic hydrocarbon polymers, polyethylene (PE), polypropylene (PP), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), polyvinyl chloride (PVC), polysulfone, polyethersulfone, polyphenylene sulfone, polyphenylene sulfide (PPS), poly(aryl ether sulfone), polystyrene, polyethylene oxide, copolymers thereof, hydrophilic treatments thereof, mixtures thereof, and combinations thereof.

[0029] Typically, the first material can be treated to be hydrophilic according to any suitable method known in the art that is advantageous to the composite material described herein. In some embodiments, its hydrophilic form is achieved by coating it with a surfactant or other polymer and / or by chemically functionalizing it with plasma and / or UV treatment.

[0030] Typically, the fluid-permeable portion can be any suitable fluid-permeable portion known in the art that is advantageous to the composite material described herein. In some embodiments, the fluid-permeable portion is selected from pores, grooves, ridges, pits, indentations, voids, through-holes, and combinations thereof. The fluid-permeable portion is configured to receive a liquid component comprising a second material and a liquid carrier. The liquid component is then cured to provide mechanical interlocking between the first and second materials.

[0031] Typically, the fluid-permeable portion of the first material may contain any suitable amount of the second material known in the art that is advantageous to the composite material described herein. The portions of the fluid-permeable portion of the first material containing the second material (e.g., at the interface) may be partially or completely filled, such that they are either porous or non-porous, respectively.

[0032] In some embodiments, the second material is contained in about 1% to about 100%, about 10% to about 90%, about 20% to about 80%, about 30% to about 70%, about 40% to about 60%, or about 50% to about 60% of the fluid-permeable portion of the first material at the interface. In these embodiments, the percentage of the interface comprising the second material contained in the fluid-permeable portion of the first material includes the total amount of the interface and is not limited to a single or specific portion of the interface.

[0033] Typically, the liquid component can be any suitable liquid component known in the art that is advantageous to the composite material described herein. In some embodiments, the liquid component includes a second material and a liquid carrier. In some embodiments, the liquid component does not include a molten polymer. In some embodiments, the liquid component is selected from dispersions, emulsions, solutions, and combinations thereof.

[0034] Typically, the liquid carrier can be any suitable liquid carrier known in the art that is advantageous to the composite material described herein. Suitable liquid carriers include solvents that do not dissolve the first component and / or do not deform the fluid-permeable portion. In some embodiments, the liquid carrier is selected from water, aliphatic alcohols (e.g., methanol, ethanol, propanol, isopropanol, butanol, etc.), non-aliphatic alcohols, and combinations thereof.

[0035] In some embodiments, the fluid-permeable portion is symmetrical, homogeneous, and / or uniform. In some embodiments, the fluid-permeable portion has symmetrically, homogeneously, and / or uniformly distributed holes, grooves, ridges, pits, indentations, pores, through-holes, or combinations thereof.

[0036] In some embodiments, the fluid-permeable portion is asymmetrical, heterogeneous, and / or non-uniform. In some embodiments, the fluid-permeable portion has asymmetrically, heterogeneously, and / or non-uniformly distributed pores, grooves, ridges, pits, indentations, holes, through-holes, or combinations thereof. In some embodiments, the fluid-permeable portion has a first portion of pores, grooves, ridges, pits, indentations, holes, through-holes, or combinations thereof, which differs from a second portion of pores, grooves, ridges, pits, indentations, holes, through-holes, or combinations thereof.

[0037] Figure 10This is an exemplary diagram of the first component 1010. In this exemplary embodiment, the first component 1010 depicts an exemplary first component and is not intended to limit the composition embodiments. In this exemplary embodiment, the first component 1010 includes a first material comprising a fluid-permeable portion 1012 and a non-fluid-permeable portion 1014. The fluid-permeable portion 1012 is asymmetrical because the left side of the diagram includes a larger and deeper region into which fluid can permeate, while the right side of the diagram includes a smaller and shallower region into which fluid can permeate.

[0038] In some embodiments, the fluid-permeable portion includes a porous portion. The porous portion may include a polymer that does not have chemically reactive functional groups in its polymer structure. In some embodiments, the porous portion may include a polyolefin, such as polyethylene (PE), including but not limited to ultra-high molecular weight polyethylene (UHMWPE), low-density polyethylene (LDPE), and high-density polyethylene (HDPE), or polypropylene (PP). In some embodiments, the porous portion may include a fluoropolymer suitable for water electrolysis applications, such as polytetrafluoroethylene (PTFE) or expanded polytetrafluoroethylene (ePTFE) or polyvinylidene fluoride (PVDF), polyvinyl chloride (PVC), polystyrene, polysulfone, polyethersulfone, polyphenylene sulfone or polyaryl ethersulfone, polyphenylene sulfide (such as Zirfon), etc. ® (partitions) or combinations thereof.

[0039] The porous portion can be hydrophobic or hydrophilic, as measured, for example, by the contact angle method. The hydrophilicity of the porous polymer portion can be increased by adding additives or inorganic materials (such as metal oxides) to the polymer, thereby forming a polymer composite. The metal oxide can be selected from zirconium oxide, titanium oxide, bismuth oxide, cerium oxide, magnesium oxide, and combinations thereof. Other hydrophilic particles that can be used include nitrides and carbides of Group IV elements in the periodic table. The hydrophilic particles can have particle sizes of 0.5 μm to 2 μm, 0.15 μm to 1.00 μm, or 0.15 μm to 0.75 μm. Composites of polymers (such as polyethylene and / or polysulfone) and inorganic materials (such as silica, titanium dioxide, and / or zirconium oxide) (integrated into the polymer matrix) can be used to improve the hydrophilicity of the porous portion.

[0040] In some embodiments, the porous portion includes an average pore size ranging from about 0.1 μm to about 4 μm. In some embodiments, the porous portion includes an average pore size ranging from about 0.1 μm to about 2 μm. In some embodiments, the porous portion includes an average pore size ranging from about 0.1 μm to about 1 μm. In some embodiments, the porous portion includes an average pore size ranging from about 0.5 μm to about 4 μm. In some embodiments, the porous portion includes an average pore size ranging from about 0.5 μm to about 3 μm. In some embodiments, the porous portion includes an average pore size ranging from about 0.5 μm to about 2 μm. In some embodiments, the porous portion includes an average pore size ranging from about 0.5 μm to about 1 μm. The average pore size can be measured, for example, by a capillary flow pore size analyzer.

[0041] In some embodiments, the porous portion comprises a porosity percentage ranging from about 1% to about 99%. In some embodiments, the porous portion comprises a porosity percentage ranging from about 10% to about 90%. In some embodiments, the porous portion comprises a porosity percentage ranging from about 20% to about 80%. In some embodiments, the porous portion comprises a porosity percentage ranging from about 30% to about 70%. In some embodiments, the porous portion comprises a porosity percentage ranging from about 40% to about 60%. In some embodiments, the porous portion comprises a porosity percentage ranging from about 40% to about 80%. In some embodiments, the porous portion comprises a porosity percentage ranging from about 50% to about 80%. In some embodiments, the porous portion comprises a porosity percentage ranging from about 60% to about 80%. In some embodiments, the porous portion comprises a porosity percentage ranging from about 50% to about 70%.

[0042] By way of example and not limitation, the first material may be formed by casting, extrusion, phase inversion, weaving or nonwoven processes, including but not limited to woven or nonwoven fabrics, spunbond mats, webs, nets, or cast or extruded layers or films. The first material may include one or more layers, or other structures or forms, or combinations thereof.

[0043] In some embodiments, the first material does not include woven fabric. In some embodiments, the first material does not include fabric. In some embodiments, the first material is nonwoven and / or solid.

[0044] Typically, the porous portion may comprise any suitable thickness known in the art that is advantageous to the composite material described herein. In some embodiments, the porous portion has a thickness ranging from about 1 μm to about 300 μm. In some embodiments, the porous portion has a thickness ranging from about 50 μm to about 250 μm. In some embodiments, the porous portion has a thickness ranging from about 75 μm to about 225 μm. In some embodiments, the porous portion has a thickness ranging from about 100 μm to about 150 μm.

[0045] Typically, the second material can be any suitable material known in the art that is advantageous to the composite material described herein. In some embodiments, the second material is a polymer that can be loaded in a solvent system. In some embodiments, the second material is selected from hydrocarbon polymer electrolytes, partially fluorinated polymer electrolytes, fully fluorinated polymer electrolytes, ionomers, cation exchange polymers, anion exchange polymers, sulfonated tetrafluoroethylene polymers, sulfonated tetrafluoroethylene vinyl fluoropolymer copolymers, fluorinated sulfonic acids or their sulfonates (such as perfluorosulfonic acid (PFSA) polymers (e.g., Nafion™ polymers) or their sulfonates), copolymers thereof, and combinations thereof.

[0046] Fluorinated sulfonic acids and fluorinated sulfonates can be prepared by hydrolyzing a fluorinated sulfonyl fluoropolymer and then optionally protonating it. Suitable fluorinated sulfonyl fluoropolymers comprise at least one repeating fluorinated sulfonyl fluoride unit and optionally one or more repeating units generated by the free radical polymerization of at least one fluorinated sulfonyl fluoride monomer and optionally one or more monomers. In some embodiments, the sulfonyl fluoropolymer is a copolymer prepared from two or more monomers. In addition to sulfonyl fluoride monomers, suitable comonomers include, but are not limited to, tetrafluoroethylene (TFE), hexafluoropropylene, vinyl fluoride, vinylidene fluoride, trifluoroethylene, chlorotrifluoroethylene, perfluoro(alkyl vinyl ethers), and mixtures thereof. For example, it can be a copolymer of a sulfonyl fluoride-containing monomer with TFE, producing a repeating unit -[CF2-CF2]-, or a copolymer with other comonomers. Monomers having side-chain phosphonic acid groups can also be incorporated into the fluorinated sulfonyl fluoropolymer to produce, upon conversion, a fluorinated ionomer containing both sulfonic acid groups and / or sulfonate groups and phosphonic acid groups and / or phosphonate groups.

[0047] A preferred class of fluorinated sulfonyl fluoropolymers includes those having the formula -(O-CF2CFR) f ) a -O-CF2CFR 'f SO2F represents a highly fluorinated, preferably perfluorinated, carbon backbone with side chains, where R f and R' fThe polymer is independently selected from F, Cl, or a perfluorinated alkyl group having 1 to 10 carbon atoms, and a = 0, 1, or 2. These polymers are converted into sulfonates or sulfonic acids, such as those disclosed in U.S. Patent Nos. 3,282,875, 4,358,545, or 4,940,525.

[0048] A preferred fluorinated sulfonyl fluoride polymer comprises a perfluorinated carbon backbone and a side chain represented by the formula -O-CF2CF(CF3)-O-CF2CF2SO2F. Fluorinated ionomers containing this type of sulfonate or sulfonic acid groups are disclosed in U.S. Patent No. 3,282,875 and can be prepared by copolymerizing tetrafluoroethylene (TFE) and perfluorinated vinyl ether CF2=CF-O-CF2CF(CF3)-O-CF2CF2SO2F, perfluorinated (3,6-dioxa-4-methyl-7-octenesulfonyl fluoride) (PSEPVE, also known as long side chain or LSC), followed by hydrolysis of the sulfonyl fluoride groups to convert them to sulfonate groups, and, if required for a particular application, to proton or salt forms. Another preferred fluorinated sulfonyl fluoride polymer is of the type disclosed in U.S. Patent Nos. 4,358,545 and 4,940,525, having the side chain -O-CF2CF2SO2F. This polymer can be prepared by copolymerizing TFE with perfluorovinyl ether CF2=CF-O-CF2CF2SO2F and perfluoro(3-oxa-4-pentenesulfonyl fluoride) (PFSVE, also known as short side chain or SSC), followed by hydrolysis, and then converting it to proton or salt form if required for a specific application.

[0049] Following hydrolysis and optional conversion to protonated form, a fluorinated sulfonate or sulfonic acid polymer is formed. As used herein, sulfonate or sulfonic acid group refers to a sulfonic acid group or sulfonate, preferably an alkali metal salt or ammonium salt. Preferred functional groups are represented by the formula -SO3X, where X is H, Li, Na, K, or N(R). 1 (R) 2 (R) 3 (R) 4 ), where R 1 R 2 R 3 and R 4 They are the same or different and are H, CH3, or C2H5. In an exemplary embodiment, the fluorinated sulfonate or sulfonic acid polymer is marketed under the trade name Nafion. ™ (The Chemours Company FC, LLC, Wilmington, DE) obtained the type.

[0050] For example, fluorinated sulfonates or sulfonic acids may contain repeating units:

[0051]

[0052] Where b is 0 or 1; c is an integer from 1 to 16; a is 0, 1, or 2; d is an integer from 1 to 16; R f and R' f Independently selected from F, Cl, or a perfluorinated alkyl group having 1 to 10 carbon atoms; and X is H, Li, Na, K, or N(R 1 (R) 2 (R) 3 (R) 4 ), where R 1 R 2 R 3 and R 4 They may be the same or different, and are H, CH3, or C2H5. For clarity, it should be noted that the chain segment ((CF2)) in the above structure... b -(O-(CF2CFR f ) c ) a -O-(CF2CFR' f ) d SO3X) is a side chain derived from the main chain of a perfluoropolymer. It also includes branched side chains with multiple sulfonic acid groups.

[0053] A specific ion-exchange polymer backbone may include one or more units represented by the following formula:

[0054]

[0055] Where m ranges from 1 to 6, and M is an alkali metal;

[0056]

[0057] Where m ranges from 1 to 6, and M is an alkali metal;

[0058]

[0059] Q 1 Q is a perfluoroalkylene group optionally having an ether oxygen atom. 2 R is a perfluoroalkylene group with a single bond or optionally an ether oxygen atom. f3 X is a perfluoroalkyl group optionally having an ether oxygen atom. 1 For oxygen, nitrogen, or carbon atoms, when X 1 When X is an oxygen atom, a is 0; when X is an oxygen atom... 1 When X is a nitrogen atom, a is 1, and when X... 1 When the a atom is carbon, a is 2, Y is a fluorine atom or a monovalent perfluorinated organic group, r is 0 or 1, and M is an alkali metal;

[0060]

[0061] Where R F11 C is a single bond or may have an ether oxygen atom. 1-6 Straight-chain perfluoroalkylene groups, and R F12 C 1-6 A straight-chain perfluoroalkylene group, where r is 0 or 1, and M is an alkali metal.

[0062] In some embodiments, the fluorinated sulfonate or sulfonic acid has an ion exchange rate of less than about 13.2. As used herein, ion exchange rate (IXR) refers to the relationship between the number of carbon atoms in the polymer backbone and the number of sulfonyl fluoride groups, sulfonate groups, or sulfonic acid groups. In some embodiments, the IXR of the fluorinated sulfonyl fluoride polymer can be expressed by the equation EW = (50 × IXR) + MW. sc -19 is related to the equivalent (EW) of the corresponding fluorinated sulfonate or sulfonic acid polymer, where MW sc The IXR is the molecular weight of the side chain of the fluorinated sulfonate or sulfonic acid polymer. In one aspect, the fluorinated sulfonate or sulfonic acid polymer has an IXR of less than about 13.2; in another aspect, less than about 12.7; in another aspect, less than about 12.1; and in another aspect, less than about 11.7; or any value, range, or subrange thereof. In one aspect, the fluorinated sulfonate or sulfonic acid polymer has an IXR of at least 7.1; in another aspect, at least 8.1; in another aspect, at least 9.1; and in another aspect, at least 10.1; or any value, range, or subrange thereof.

[0063] In some embodiments, the fluorinated sulfonate or sulfonic acid has an equivalent weight (EW) of less than about 1100; alternatively less than about 1000; alternatively less than about 980; alternatively less than about 950; alternatively less than about 930, or any value, range, or subrange thereof. In one aspect, the fluorinated ionomer has an EW of at least about 530; alternatively at least about 580; alternatively at least about 630; alternatively at least about 680, or any value, range, or subrange thereof. As used herein, (EW) refers to the weight of the corresponding fluorinated sulfonic acid polymer in proton form required to neutralize one equivalent of NaOH.

[0064] In some embodiments, the backbone of the ion exchange polymer comprises polyphenylene, polyphenylene ether, polysulfone, polyethylene, polyether ether ketone and / or poly(aryl ether sulfone).

[0065] In some embodiments, the second material comprises an ion-exchange polymer. The ion-exchange polymer may include one or more functional groups to improve ionic conductivity, water absorption, chemical stability, and / or mechanical properties. In some embodiments, the ion-exchange polymer is a cation-exchange polymer comprising functional groups selected from sulfonate, phosphate, derivatives thereof, and combinations thereof. In some embodiments, the ion-exchange polymer is an anion-exchange polymer comprising functional groups selected from ammonium, piperidinium, imidazolium, guanidine, benzimidazolium, pyrrolomium, spirocyclic ammonium, phosphonium, derivatives thereof, and combinations thereof. In one embodiment, the AEM separator comprises a selective material comprising poly(arylpiperidinium).

[0066] The anion exchange capacity of the cation or anion exchange polymers or polyelectrolytes applicable to this document ranges from approximately 0.8 meq / g dry polymer to 2.5 meq / g dry polymer. The particle size of the filler in the polyelectrolyte can be less than or equal to 10 μm, or less than or equal to 4 μm, or less than or equal to 3 μm, or less than or equal to 2 μm, or less than or equal to 1 μm, for example, 0.1 μm to 4 μm, or 0.2 μm to 3 μm, or 0.5 μm to 1 μm. In some embodiments, the average particle surface area is approximately 4 m². 2 / g.

[0067] Generally, the composite material can be any suitable form of composite material known in the art that is advantageous to the composite material described herein. In some embodiments, the composite material is in the form of membranes, strips, weld strips, weld media, sheets, blocks, rods, bars, tubes, and combinations thereof.

[0068] In some embodiments, a portion of the composite material is symmetrical. In some embodiments, the components of the composite material are symmetrical. In some embodiments, the entire composite material is symmetrical.

[0069] In some embodiments, a portion of the composite material is asymmetric. In some embodiments, the components of the composite material are asymmetric. In some embodiments, the entire composite material is asymmetric.

[0070] In some embodiments, the shape of the composite material is selected from symmetrical shapes, asymmetrical shapes, regular shapes, irregular shapes, and combinations thereof. In some embodiments, the shape of the composite material is selected from regular polygons, irregular polygons, circles, triangles, squares, rectangles, pentagons, hexagons, heptagons, octagons, nonagons, decagons, unelectra, dodecagons, partial shapes thereof, and combinations thereof.

[0071] In some embodiments, the components of the composite material are selected from symmetrical shapes, asymmetrical shapes, regular shapes, irregular shapes, and combinations thereof. In some embodiments, the shape of the composite material is selected from regular polygons, irregular polygons, circles, triangles, squares, rectangles, pentagons, hexagons, heptagons, octagons, nonagons, decagons, unelectra, dodecagons, partial shapes thereof, and combinations thereof.

[0072] Typically, composite materials may comprise any suitable number of components known in the art that are advantageous to the composite materials described herein. In some embodiments, the composite material comprises different interfacial components. In some embodiments, the composite material also includes interfaces within one or more components.

[0073] In some embodiments, the composite material is a three-component composite material. In these embodiments, the interface exists as a distinct third component separating the first and second components. The third component is in contact with both the first and second components. The third component can be bonded to the first and second components using any suitable bonding technique known in the art that is advantageous to the composite material described herein. The third component may be part of a monolithic or multilayered first component and represents a portion of the first component filled with the second material.

[0074] Typically, each component may comprise any suitable number of layers known in the art that are advantageous to the composite material described herein. In some embodiments, the first component comprises one, two, three, four, or more than four layers. In some embodiments, the second component comprises one, two, three, four, or more than four layers. In some embodiments, the third component comprises one, two, three, four, or more than four layers. Each layer of a component may comprise the same or different materials or any combination thereof.

[0075] In some embodiments, the first component and the second component are mechanically interlocked at the interface. In some embodiments, the first component and the second component are interlocked at the interface through entanglement of the first material and the second material. In some embodiments, the first component and the second component are not chemically bonded. In some embodiments, the first component and the second component are not thermally fused.

[0076] Typically, each component of a composite material may have any suitable thickness known in the art that is advantageous to the composite material described herein.

[0077] Typically, each component of a composite material may have any suitable hydrophobicity or hydrophilicity known in the art that is advantageous to the composite material described herein.

[0078] Typically, each component of a composite material may have any suitable homogeneity known in the art that is advantageous to the composite material described herein.

[0079] Typically, the fluid-permeable portion may have any suitable tortuosity known in the art to be advantageous to the composite material described herein.

[0080] In some embodiments, the composite material comprises a weld strip comprising at least two different materials on its outer surface, wherein these materials are mechanically entangled within an inner portion of the strip. This entanglement provides mechanical strength and adhesive force that cannot be achieved through conventional welding processes. The weld strip can be used to join two incompatible substrates, i.e., those that cannot be welded together without the weld strip. During the welding process of the two substrates, the weld strip is placed between the two substrates, wherein each surface of the weld strip is aligned with a similar welding surface of the two substrates, thereby ensuring a strong bond between the two surfaces. Therefore, the weld strip can provide good adhesive force without the need for adhesives or excessive compression of the two substrates.

[0081] Generally, composite materials can be prepared according to any suitable method known in the art that is advantageous to the composite materials described herein. In some embodiments, the composite material according to this disclosure is prepared by a method comprising: (i) receiving a liquid component comprising a second material and a liquid carrier in a fluid-permeable portion of a first material; and (ii) curing the liquid component in the fluid-permeable portion of the first material.

[0082] In some embodiments, the method includes curing all the liquid component within a fluid-permeable portion of the first material. In some embodiments, the method includes curing a portion of the liquid component outside the fluid-permeable portion of the first material. In these embodiments, the portion of the liquid component curing outside the fluid-permeable portion of the first material may cure on an outer surface of the first material.

[0083] Figure 7 This is an exemplary method flowchart 710. In this exemplary embodiment, method flowchart 710 depicts exemplary steps of a method embodiment for preparing the composite material described herein, and is not intended to limit the method embodiment. In this exemplary embodiment, the method includes receiving 712 a liquid component comprising a second material and a liquid carrier in a fluid-permeable portion of a first material, and curing 714 the liquid component in the fluid-permeable portion of the first material.

[0084] Typically, the liquid component comprising a second material and a liquid carrier can be received in a fluid-permeable portion of the first material using any suitable method known in the art that is advantageous to the composite material described herein. In some embodiments, the liquid component comprising a second material and a liquid carrier is received in a fluid-permeable portion of the first material when applied using techniques selected from: coating, slot die coating, doctor blade coating, bar coating, Mayer bar coating, gravure coating, electrophoretic coating, impregnation, spraying, and combinations thereof.

[0085] In some embodiments, the liquid component comprising the second material and the liquid carrier is received in the fluid-permeable portion of the first material at a temperature below about 50°C. In some embodiments, the liquid component comprising the second material and the liquid carrier is received in the fluid-permeable portion of the first material under ambient conditions.

[0086] Typically, the liquid component can be cured using any suitable method known in the art that is advantageous to the composite material described herein. In these embodiments, curing the liquid component results in the removal of the liquid carrier, and at least a portion of the second material is contained within the fluid-permeable portion of the first material. In some embodiments, curing the liquid component results in the removal of the liquid carrier, and all of the second material is contained within the fluid-permeable portion of the first material. In some embodiments, curing the liquid component results in the removal of the liquid carrier, and at least a portion of the second material is on the outer surface of the first material.

[0087] In some embodiments, curing the liquid component in a fluid-permeable portion of the first material includes drying the liquid carrier of the liquid component. Typically, the liquid carrier of the liquid component can be dried accordingly by any suitable drying method known in the art that is advantageous to the composite material described herein. In some embodiments, curing the liquid component in a fluid-permeable portion of the first material includes drying the liquid carrier of the liquid component at a combination of temperature and time that improves adhesion during welding. In some embodiments, curing the liquid component in a fluid-permeable portion of the first material includes drying the liquid carrier of the liquid component at an elevated temperature. In some embodiments, curing the liquid component in a fluid-permeable portion of the first material includes drying the liquid carrier of the liquid component at a temperature less than about 150°C. In some embodiments, curing the liquid component in a fluid-permeable portion of the first material includes drying the liquid carrier of the liquid component at a temperature greater than about 50°C. In some embodiments, curing the liquid component in a fluid-permeable portion of the first material includes drying the liquid carrier of the liquid component at a temperature less than the melting point of the first material.

[0088] Typically, each element of the method can be adapted according to any suitable method known in the art that is advantageous to the composite material described herein. These elements include coating techniques, linear velocity, temperature, component thickness, dispersion properties, solvents, and combinations thereof.

[0089] Suitable solvents include those that do not dissolve the first component and / or do not deform the permeable portion of the fluid. In some embodiments, the solvent is selected from water, aliphatic alcohols (e.g., methanol, ethanol, propanol, isopropanol, butanol, etc.), non-aliphatic alcohols, and combinations thereof.

[0090] Generally, composite materials can be used according to any suitable method known in the art that is advantageous to the composite materials described herein. In some embodiments, the composite material according to this disclosure is used according to a method including: (i) using the composite material to join a first surface comprising a material compatible with the first material and a second surface comprising a material compatible with the second material.

[0091] Figure 8 This is an exemplary method flowchart 810. In this exemplary embodiment, method flowchart 810 depicts exemplary steps of a method embodiment using the composite material described herein, and is not intended to limit the method embodiment. In this exemplary embodiment, the method includes using 812 composite material to join a first surface comprising a material compatible with a first material and a second surface comprising a material compatible with a second material.

[0092] Typically, the first surface and / or the second surface may each be any suitable surface known in the art that is advantageous to the composite material described herein. In some embodiments, the first surface and / or the second surface are each selected from the surface of a membrane, the surface of a separator, the surface of a separator, the surface of a fuel cell, the surface of a fuel cell stack, the surface of a battery, the surface of a flow battery, the surface of an electrolyzer, the surface of a water electrolyzer, the surface of an electrode, the surface of a cathode, the surface of an anode, the surface of a membrane electrode assembly, the surface of a catalyst, the surface of a flow field plate, the surface of a gasket, the surface of a sealing gasket, the surface of a membrane, the surface of a gas diffusion substrate, the surface of a gas diffusion electrode, the surface of a porous transport layer, a catalyst-coated membrane, and combinations thereof.

[0093] Typically, the first surface and / or the second surface may each comprise any suitable material known in the art that is advantageous to the composite material described herein. In some embodiments, the first surface and / or the second surface each comprise a material compatible with the first material and / or the second material. In some embodiments, the first surface and / or the second surface each comprise the same material as the first material and / or the second material. In some embodiments, the first surface and / or the second surface each comprise a material different from the first material and / or the second material.

[0094] In some embodiments, a welding technique is used to join the first and second surfaces to the composite material, respectively. This welding technique is selected from ultrasonic welding, hot gas welding, high-speed tip welding, injection welding, vibration welding, laser welding, rotary welding, infrared welding, induction welding, high-frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0095] In some embodiments, the method further includes using welding techniques to join each of the first and second surfaces to the composite material, the welding techniques being selected from ultrasonic welding, hot gas welding, high-speed tip welding, injection welding, vibration welding, laser welding, rotary welding, infrared welding, induction welding, high-frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0096] In some embodiments, the composite material can be extended onto a gas diffusion substrate, a porous transport layer, and / or a catalyst layer. Additional entanglement between the composite material and the gas diffusion material or porous transport layer can further increase the bond strength.

[0097] Membrane electrode assemblies (MEAs) are commonly used in energy conversion systems, including fuel cells and water electrolyzers. An MEA consists of a membrane at the center, catalyst layers adjacent to both sides of the membrane, and a gas diffusion substrate or porous transport layer on the outer surface of the assembly.

[0098] MEAs can be prepared by several methods. For example, an electrocatalyst can be applied to a gas diffusion substrate to form a gas diffusion electrode. Two gas diffusion electrodes can be pressed onto a membrane to form a MEA. Alternatively, an electrocatalyst layer can first be coated on both sides of the membrane to form a catalyst-coated membrane (CCM). Then, a gas diffusion substrate can be applied to the CCM, making it adjacent to the electrocatalyst layer. In some applications, a porous transport layer can be used instead of a gas diffusion substrate.

[0099] In some embodiments, a membrane electrode assembly (MEA) comprising a composite material is described herein. In some embodiments, an assembly comprising an MEA is described herein.

[0100] Figure 9This is an exemplary diagram of component 910. In this exemplary embodiment, component 910 depicts an exemplary component and is not intended to limit the composition implementation. In this exemplary embodiment, component 910 includes a first sealing gasket 912, a first composite material 914, an electrocatalyst 916 disposed on a membrane 918, a second composite material 920, and a second sealing gasket 920. The electrocatalyst 916 disposed on the membrane 918 is part of a membrane electrode assembly, which may further include one or more gas diffusion substrates, a porous transport layer, and a second electrocatalyst (not shown). The composite material enables the membrane electrode assembly to be coupled to two non-porous gaskets.

[0101] In some embodiments, a membrane electrode assembly (MEA) is described herein, comprising: a membrane; at least one electrocatalyst layer disposed on one side of the membrane; optionally, at least one gas diffusion substrate and / or porous transport layer in physical contact with the at least one electrocatalyst layer; and a composite material comprising: a first component comprising a first material having a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component separating at least a portion of the first component from the second component; wherein the composite material is coupled to a first surface comprising a material compatible with the first material and / or a second surface comprising a material compatible with the second material; and wherein the first surface and / or the second surface are each selected from the surface of a sealing gasket, the surface of the membrane, the surface of the at least one electrocatalyst layer, the surface of the at least one gas diffusion substrate, and combinations thereof.

[0102] In some embodiments, a welding technique is used to join the first surface and / or the second surface to the composite material, the welding technique being selected from ultrasonic welding, hot gas welding, high-speed tip welding, injection welding, vibration welding, laser welding, rotary welding, infrared welding, induction welding, high-frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0103] In some embodiments, only the first surface is bonded to the composite material. In some embodiments, only the second surface is bonded to the composite material. In some embodiments, both the first and second surfaces are bonded to the composite material.

[0104] Typically, at least one electrocatalyst layer may comprise any suitable number of electrocatalyst layers known in the art as advantageous to the composite material described herein. In some embodiments, at least one electrocatalyst layer comprises two electrocatalyst layers disposed on different sides of the membrane. In some embodiments, at least one electrocatalyst layer comprises two electrocatalyst layers disposed on opposite sides of the membrane.

[0105] Typically, at least one gas diffusion substrate may comprise any suitable number of gas diffusion substrates or porous transport layers known in the art to be advantageous to the composite material described herein. In some embodiments, at least one gas diffusion substrate comprises two gas diffusion substrates, wherein the two gas diffusion substrates are in physical contact with different electrocatalyst layers.

[0106] In some embodiments, at least one gas diffusion substrate and / or porous transport layer is aligned with at least one electrocatalyst layer. In these embodiments, the at least one gas diffusion substrate may be smaller than the at least one electrocatalyst layer, such that a portion of the at least one electrocatalyst layer is not covered by the at least one gas diffusion substrate. Alternatively, the at least one gas diffusion substrate may be larger than the at least one electrocatalyst layer, such that the at least one electrocatalyst layer is completely covered by the at least one gas diffusion substrate.

[0107] In some embodiments, the composite material contacts the edge of each of the two electrocatalyst layers. In these embodiments, the composite material forms the edge layer of the MEA.

[0108] In some embodiments, the composite material is in contact with the edge of at least one gas diffusion substrate and / or porous transport layer.

[0109] In some embodiments, this document describes a component comprising: at least one sealing gasket including a first surface and / or a second surface, the first surface comprising a material compatible with the first material, the second surface comprising a material compatible with the second material; and MEA; wherein the composite material is coupled to the first surface and / or the second surface of the at least one sealing gasket.

[0110] In some embodiments, a welding technique is used to attach at least one first surface of a sealing gasket and / or at least one second surface of a sealing gasket to the composite material, the welding technique being selected from ultrasonic welding, hot gas welding, high-speed tip welding, injection welding, vibration welding, laser welding, rotary welding, infrared welding, induction welding, high-frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0111] In some implementations, the component includes at least two sealing gaskets, wherein each of the at least two sealing gaskets is coupled to the composite material.

[0112] In some embodiments, the component is a sealing component. In these embodiments, a seal is formed by a connection between at least two sealing gaskets and the composite material.

[0113] Typically, the membrane may comprise any suitable material known in the art that is advantageous to the composite material described herein. In some embodiments, the membrane comprises a polymer that is the same as or similar to the second material of the composite material. In some embodiments, the membrane comprises a polymer selected from hydrocarbon polymer electrolytes, partially fluorinated polymer electrolytes, fully fluorinated polymer electrolytes, ionomers, cation exchange polymers, anion exchange polymers, sulfonated tetrafluoroethylene polymers, sulfonated tetrafluoroethylene vinyl fluoropolymer copolymers, fluorinated sulfonic acids or their sulfonates (such as perfluorosulfonic acid (PFSA) polymers (e.g., Nafion™ polymers) or their sulfonates), copolymers thereof, and combinations thereof. In some embodiments, the membrane comprises a perfluorinated sulfonate ionomer or anion exchange membrane.

[0114] In some embodiments, the membrane, diaphragm, or separator includes a reinforcing material. The reinforcing material may include any suitable reinforcing material known in the art, including PTFE, ePTFE, PEEK, PES, PE, PP, PPS, or any combination thereof, including mesh, membrane, woven, nonwoven, and expanded forms.

[0115] In some implementations, the membrane comprises multiple material layers and additives, such as gas reforming catalysts, free radical scavenging substances, and combinations thereof.

[0116] Typically, the electrocatalyst layer may comprise any suitable material known in the art that is advantageous to the composite material described herein. In some embodiments, the electrocatalyst layer comprises at least one electrocatalyst and at least one ionically conductive polymer as a binder. The electrocatalyst may comprise a fine metal powder and / or may be supported on a conductive carbon-based powder. The electrocatalyst metal may be selected from platinum group metals (including platinum, palladium, iridium, ruthenium, rhodium, or osmium), their oxides, their alloys, and combinations thereof.

[0117] Typically, at least one gas diffusion substrate may comprise any suitable gas diffusion substrate known in the art that is advantageous to the composite material described herein. In some embodiments, at least one gas diffusion substrate comprises carbon paper, woven carbon cloth, nonwoven carbon fiber mesh, or combinations thereof.

[0118] Typically, at least one porous transport layer may comprise any suitable porous transport layer known in the art that is advantageous to the composite material described herein. In some embodiments, the at least one porous transport layer comprises a structure selected from felt, sintered powder sheets, foam, woven mesh, fine mesh, perforated patterned sheets, and combinations thereof. The at least one porous transport layer may be made of metal, metal oxide, and / or alloy, including stainless steel, nickel, titanium, titanium oxide, and combinations thereof. The at least one porous transport layer may comprise TiO2. x TaO x NbO x NiCoO x Ta, Nb, Zr, Ni, TiN x TaN x ZrN x TaC x CrC x TiB2, TaB x Coatings of other materials or mixtures thereof.

[0119] In many embodiments, the product includes a composite material according to this disclosure. In some embodiments, the composite material will comprise a first surface of a first material and a second surface comprising a second material. In some embodiments, the product includes an MEA. In some embodiments, the product includes a component.

[0120] Figure 2 This is an exemplary diagram of product 210. In this exemplary embodiment, product 210 depicts an exemplary product and is not intended to limit the composition of the embodiment. In this exemplary embodiment, product 210 includes a first surface 212 and a second surface 214, the first surface including a first material and the second surface including a second material. The first surface 212 is bonded to the second surface 214 via a composite material 110. The first surface 212 has the same or similar material as the first component 112, and the second surface 214 has the same or similar material as the second component 114.

[0121] Figure 3This is an exemplary diagram of a composite material 310 comprising two composite materials 110 joined together by a common material. In this exemplary embodiment, composite material 310 depicts an exemplary composite material and is not intended to limit the composition embodiments. In this exemplary embodiment, composite material 310 includes a first component 314, a second component 312, and an interface 316. The first component includes a first material having a fluid-permeable portion, and the second component includes a second material incompatible with the first material. Interface 316 includes the second material contained within the fluid-permeable portion of the first material. Composite material 310 also includes a third component 320 and an interface 318, the third component including a third material incompatible with the first material. Interface 318 includes the second material contained within the fluid-permeable portion of the third material. Interfaces 316 and 318 may be the same or different. The first component 314 and the third component 320 may be the same or different. Although the exemplary embodiment depicts the second component 312 as a common material, this depiction is non-limiting. Alternatively, either the first component 314 or the third component 320 may be used as a common material. Although the exemplary embodiments depict the first component 314, the second component 312, the interface 316, the interface 318, and the third component 320 as having certain dimensions and thicknesses, this depiction is not limiting.

[0122] Figure 4 This is an exemplary diagram of product 410. In this exemplary embodiment, product 410 depicts an exemplary product and is not intended to limit the composition of the embodiment. This exemplary diagram is... Figure 9 When the components described in the text are welded together Figure 9 A cross-sectional view of the component. Figure 4 Composite material 310 corresponds to first composite material 914 and second composite material 920, and membrane 416 corresponds to membrane 918. That is, the upper half of composite material 310 belongs to the first composite material, and the lower half of composite material 310 belongs to the second composite material, such that membrane 416 is sandwiched between the two composite materials. More specifically, in an exemplary embodiment, product 410 includes a first electrocatalyst layer 412 and a second electrocatalyst layer 414 disposed on membrane 416. Membrane 416 includes a material incompatible with the material of the first component 314. The first electrocatalyst 412 and the second electrocatalyst 414 disposed on membrane 416 are part of a membrane electrode assembly, which may also include one or more gas diffusion substrates or porous transport layers (not shown). The composite materials enable the membrane electrode assembly to be coupled to two sealing gaskets. Membrane 416 is bonded to composite material 310 at its peripheral edges.

[0123] Figure 5This is an exemplary diagram of composite material 510. In this exemplary embodiment, composite material 510 depicts an exemplary composite material and is not intended to limit the composition embodiments. In this exemplary embodiment, composite material 510 includes a first component 512, a second component 514, and an interface 516. The first component includes a first material having a fluid-permeable portion, and the second component includes a second material incompatible with the first material. Interface 516 includes the second material contained within the fluid-permeable portion of the first material. In this exemplary embodiment, composite material 510 is configured such that it can be wound around components used for bonding. Although this exemplary embodiment depicts the first component 512, the second component 514, and the interface 516 as having certain dimensions and thicknesses, this depiction is non-limiting.

[0124] Figure 6 This is an exemplary diagram of product 610. In this exemplary embodiment, product 610 depicts an exemplary product and is not intended to limit the composition of the embodiment. In the exemplary embodiment, product 610 includes a first electrocatalyst 612 and a second electrocatalyst 614. The first electrocatalyst 612 and the second electrocatalyst 614 are separated by a membrane 616. The membrane 616 includes a material compatible with the material of the first component 512. The membrane 616 is bonded to at least one composite material 510 at its peripheral edge. The at least one composite material 510 may be a single composite material 510 or may include more than one composite material 510. In the case where the at least one composite material 510 is a single composite material 510, the depicted composite material 510 is a single composite material that surrounds the membrane 616 and contacts the membrane 616 at its peripheral edge. In the case where the at least one composite material 510 includes more than one composite material 510, the depicted composite materials 510 are different composite materials, each contacting the membrane 616 at its peripheral edge.

[0125] In some embodiments, the product is configured for use for an extended period of time. In some embodiments, the product is configured for use under elevated pressure and / or temperature. In some embodiments, the product is configured for use under differential pressure and / or temperature. In some embodiments, the product is configured for use under elevated pressure and / or temperature for an extended period of time. In some embodiments, the long duration is in the range of about 1 year to about 20 years. In some embodiments, the long duration is in the range of about 5 years to about 20 years. In some embodiments, the long duration is in the range of about 10 years to about 20 years. In some embodiments, the long duration is greater than about 20 years.

[0126] In some embodiments, the increased pressure or pressure difference is in the range of about 100 kPa to about 10,000 kPa. In some embodiments, the increased pressure or pressure difference is in the range of about 100 kPa to about 8,000 kPa. In some embodiments, the increased pressure or pressure difference is in the range of about 100 kPa to about 5,000 kPa. In some embodiments, the increased pressure or pressure difference is in the range of about 100 kPa to about 2,000 kPa. In some embodiments, the increased pressure or pressure difference is in the range of about 1,000 kPa to about 10,000 kPa. In some embodiments, the increased pressure or pressure difference is in the range of about 1,000 kPa to about 8,000 kPa. In some embodiments, the increased pressure or pressure difference is in the range of about 1,000 kPa to about 5,000 kPa. In some embodiments, the increased pressure or pressure difference is in the range of about 1,000 kPa to about 2,000 kPa. In some embodiments, the increased pressure or pressure difference is in the range of about 2,000 kPa to about 10,000 kPa. In some embodiments, the increased pressure or pressure differential is in the range of about 2000 kPa to about 8000 kPa. In some embodiments, the increased pressure or pressure differential is in the range of about 2000 kPa to about 5000 kPa.

[0127] In some embodiments, the temperature or temperature difference is in the range of about 20°C to about 120°C. In some embodiments, the temperature or temperature difference is in the range of about 20°C to about 80°C. In some embodiments, the temperature or temperature difference is in the range of about 20°C to about 60°C. In some embodiments, the temperature or temperature difference is in the range of about 20°C to about 40°C. In some embodiments, the temperature or temperature difference is in the range of about 40°C to about 120°C. In some embodiments, the temperature or temperature difference is in the range of about 40°C to about 80°C. In some embodiments, the temperature or temperature difference is in the range of about 20°C to about 60°C. In some embodiments, the temperature or temperature difference is in the range of about 60°C to about 80°C.

[0128] In some embodiments, the first surface and / or the second surface are each selected from the surface of a membrane, the surface of a diaphragm, the surface of a separator, the surface of a fuel cell, the surface of a fuel cell stack, the surface of a battery, the surface of a flow battery, the surface of an electrolyzer, the surface of a water electrolyzer, the surface of an electrode, the surface of a cathode, the surface of an anode, the surface of a membrane electrode assembly, the surface of a catalyst, the surface of a flow field plate, the surface of a gasket, the surface of a sealing gasket, the surface of a membrane, the surface of a gas diffusion substrate, the surface of a gas diffusion electrode, the surface of a porous transport layer, a catalyst-coated membrane, and combinations thereof.

[0129] In some embodiments, a welding technique is used to join the first and second surfaces to the composite material, respectively. This welding technique is selected from ultrasonic welding, hot gas welding, high-speed tip welding, injection welding, vibration welding, laser welding, rotary welding, infrared welding, induction welding, high-frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0130] In some implementations, the product is selected from fuel cell stacks, fuel cells, fuel cell stacks, batteries, mobile batteries, electrolyzers, water electrolyzers, and combinations thereof.

[0131] Further aspects of this disclosure are provided by the subject matter of the following provisions:

[0132] 1. A composite material, said composite material comprising:

[0133] A first component, the first component comprising a first material having a fluid-permeable portion; and

[0134] The second component includes a second material that is incompatible with the first material;

[0135] The first component and the second component are joined at an interface, the interface comprising the second material contained within the fluid-permeable portion of the first material; and

[0136] The interface forms a third component that separates at least a portion of the first component from the second component.

[0137] 2. The composite material according to the foregoing clause, wherein the first material is selected from porous polymer materials, polyolefins, aromatic hydrocarbon polymers, polyethylene (PE), polypropylene (PP), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), polyvinyl chloride (PVC), polysulfone, polyethersulfone, polyphenylene sulfone, polyphenylene sulfide (PPS), poly(aryl ether sulfone), polystyrene, polyethylene oxide, copolymers thereof, hydrophilic treatments thereof, mixtures thereof, and combinations thereof.

[0138] 3. The composite material according to any of the preceding clauses, wherein the fluid-permeable portion is selected from pores, grooves, ridges, pits, indentations, holes, through holes, and combinations thereof.

[0139] 4. The composite material according to any of the preceding clauses, wherein the second material is selected from hydrocarbon polymer electrolytes, partially fluorinated polymer electrolytes, fluorinated polymer electrolytes, ionomers, cation exchange polymers, anion exchange polymers, sulfonated tetrafluoroethylene polymers, sulfonated tetrafluoroethylene vinyl fluoropolymer copolymers, perfluorosulfonic acid (PFSA) polymers, copolymers thereof, their sulfonates, and combinations thereof.

[0140] 5. The composite material according to any of the preceding clauses, wherein the interface is formed by a method comprising:

[0141] Receives a liquid component comprising the second material and a liquid carrier in the fluid-permeable portion of the first material; and

[0142] The liquid component is solidified in the fluid-permeable portion of the first material.

[0143] 6. The composite material according to any of the preceding clauses, wherein the composite material is selected from membranes, strips, welding strips, welding media, sheets, blocks, rods, tubes, and combinations thereof.

[0144] 7. The composite material according to any of the preceding clauses, wherein the first component and the second component are mechanically interlocked at the interface.

[0145] 8. A product comprising a composite material according to any of the preceding clauses, wherein the composite material comprises a first surface of a material compatible with the first material and a second surface comprising a material compatible with the second material.

[0146] 9. The product as described in the foregoing clause, wherein the product is configured for use for an extended period of time under elevated pressure and / or temperature.

[0147] 10. The product according to any of the preceding clauses, wherein the first surface and / or the second surface are each selected from the surface of a membrane, the surface of a diaphragm, the surface of a separator, the surface of a fuel cell, the surface of a fuel cell stack, the surface of a battery, the surface of a flow battery, the surface of an electrolyzer, the surface of a water electrolyzer, the surface of an electrode, the surface of a cathode, the surface of an anode, the surface of a membrane electrode assembly, the surface of a catalyst, the surface of a flow field plate, the surface of a gasket, the surface of a sealing gasket, the surface of a gas diffusion substrate, the surface of a gas diffusion electrode, the surface of a porous transport layer, a catalyst-coated membrane, and combinations thereof.

[0148] 11. The product according to any of the preceding clauses, wherein the membrane, diaphragm and separator further include reinforcing material.

[0149] 12. The product according to the foregoing clauses, wherein the reinforcing material is PTFE, ePTFE, PEEK, PES, PE, PP, PPS or a combination thereof.

[0150] 13. The product according to any of the preceding clauses, wherein the product is selected from the surface of a membrane, the surface of a diaphragm, the surface of a separator, the surface of a fuel cell, the surface of a fuel cell stack, the surface of a battery, the surface of a flow battery, the surface of an electrolyzer, the surface of a water electrolyzer, the surface of an electrode, the surface of a cathode, the surface of an anode, the surface of a membrane electrode assembly, the surface of a catalyst, the surface of a flow field plate, the surface of a gasket, the surface of a sealing gasket, the surface of a gas diffusion substrate, the surface of a gas diffusion electrode, the surface of a porous transport layer, a catalyst-coated membrane, and combinations thereof.

[0151] 14. A membrane electrode assembly (MEA) comprising a composite material according to any of the preceding clauses.

[0152] 15. A method for preparing a composite material, the composite material comprising:

[0153] A first component, the first component comprising a first material having a fluid-permeable portion; and

[0154] The second component includes a second material that is incompatible with the first material;

[0155] The first component and the second component are joined at an interface, the interface comprising the second material contained within the fluid-permeable portion of the first material; and

[0156] The interface forms a third component that separates at least a portion of the first component from the second component, and the method includes:

[0157] Receives a liquid component comprising the second material and a liquid carrier in the fluid-permeable portion of the first material; and

[0158] The liquid component is solidified in the fluid-permeable portion of the first material.

[0159] 16. The method according to the foregoing clause, wherein when the liquid component is applied using a technique selected from: coating, slot die coating, doctor blade coating, bar coating, Mayer bar coating, gravure coating, electrophoretic coating, impregnation, spraying, and combinations thereof.

[0160] 17. The method according to any of the preceding clauses, wherein the liquid component is received in the fluid-permeable portion of the first material at a temperature below about 50°C.

[0161] 18. The method according to any of the preceding clauses, wherein curing the liquid component in the fluid-permeable portion of the first material comprises drying the liquid component.

[0162] 19. A method of using a composite material, the composite material comprising:

[0163] A first component, the first component comprising a first material having a fluid-permeable portion; and

[0164] The second component includes a second material that is incompatible with the first material;

[0165] The first component and the second component are joined at an interface, the interface comprising the second material contained within the fluid-permeable portion of the first material; and

[0166] The interface forms a third component that separates at least a portion of the first component from the second component, and the method includes:

[0167] The composite material is used to join a first surface comprising a material compatible with the first material and a second surface comprising a material compatible with the second material.

[0168] 20. The method according to the foregoing clause, wherein the first surface and / or the second surface are each selected from the surface of a membrane, the surface of a diaphragm, the surface of a separator, the surface of a fuel cell, the surface of a fuel cell stack, the surface of a battery, the surface of a flow battery, the surface of an electrolyzer, the surface of a water electrolyzer, the surface of an electrode, the surface of a cathode, the surface of an anode, the surface of a membrane electrode assembly, the surface of a catalyst, the surface of a flow field plate, the surface of a gasket, the surface of a sealing gasket, the surface of a gas diffusion substrate, the surface of a gas diffusion electrode, the surface of a porous transport layer, a catalyst-coated membrane, and combinations thereof.

[0169] 21. The product according to any of the preceding clauses, wherein the membrane, diaphragm and separator further include reinforcing material.

[0170] 22. The product according to the foregoing clauses, wherein the reinforcing material is PTFE, ePTFE, PEEK, PES, PE, PP, PPS or a combination thereof.

[0171] 23. The method according to any of the preceding clauses, wherein each of the first surface and the second surface is joined to the composite material using a welding technique selected from ultrasonic welding, hot gas welding, high-speed tip welding, injection welding, vibration welding, laser welding, rotary welding, infrared welding, induction welding, high-frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0172] 24. A membrane electrode assembly (MEA), the membrane electrode assembly comprising:

[0173] membrane;

[0174] At least one electrocatalyst layer is disposed on one side of the membrane;

[0175] Optionally, at least one gas diffusion substrate and / or porous transport layer in physical contact with the at least one electrocatalyst layer; and

[0176] Composite material, the composite material comprising:

[0177] A first component, the first component comprising a first material having a fluid-permeable portion; and

[0178] The second component includes a second material that is incompatible with the first material;

[0179] The first component and the second component are joined at an interface, the interface comprising the second material contained within the fluid-permeable portion of the first material; and

[0180] The interface forms a third component that separates at least a portion of the first component from the second component;

[0181] The composite material is bonded to a first surface comprising a material compatible with the first material and / or a second surface comprising a material compatible with the second material; and

[0182] The first surface and / or the second surface are each selected from the surface of the membrane, the surface of the gasket, the surface of the sealing gasket, the surface of the at least one electrocatalyst layer, the surface of the at least one gas diffusion substrate and / or porous transport layer, the surface of the electrolyzer, and combinations thereof.

[0183] 25. The MEA according to the foregoing clause, wherein the first surface and / or the second surface are respectively joined to the composite material using welding techniques selected from ultrasonic welding, hot gas welding, high-speed tip welding, injection welding, vibration welding, laser welding, rotary welding, infrared welding, induction welding, high-frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0184] 26. The MEA according to any of the preceding clauses, wherein the at least one electrocatalyst layer comprises two electrocatalyst layers disposed on different sides of the membrane.

[0185] 27. The MEA according to any of the preceding clauses, wherein the at least one gas diffusion substrate comprises two gas diffusion substrates, wherein the two gas diffusion substrates are in physical contact with different electrocatalyst layers.

[0186] 28. The MEA according to any of the preceding clauses, wherein the composite material is in edge contact with each of the two electrocatalyst layers and / or at least one gas diffusion substrate and / or porous transport layer.

[0187] 29. A component, the component comprising:

[0188] At least one sealing gasket, the at least one sealing gasket including a first surface and / or a second surface, the first surface including a material compatible with the first material, and the second surface including a material compatible with the second material; and

[0189] MEA as described in any of the foregoing clauses;

[0190] The composite material is coupled to the first surface of the at least one sealing gasket and / or the second surface of the at least one sealing gasket.

[0191] 30. The component according to the foregoing clause, wherein the first surface of the at least one sealing gasket and / or the second surface of the at least one sealing gasket are respectively joined to the composite material using welding technology, the welding technology being selected from ultrasonic welding, hot gas welding, high-speed tip welding, injection welding, vibration welding, laser welding, rotary welding, infrared welding, induction welding, high-frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0192] 31. The component according to any of the preceding clauses, the component comprising at least two sealing gaskets, wherein each of the at least two sealing gaskets is coupled to the composite material.

[0193] 32. The component according to any of the preceding clauses, wherein the component is a sealing component.

[0194] 33. A product comprising the components described in any of the preceding clauses.

[0195] 34. The product as described in the foregoing clause, wherein the product is configured to be used for an extended period of time under elevated pressure and / or temperature.

[0196] 35. The product according to any of the preceding clauses, wherein the product is selected from fuel cell stacks, fuel cells, fuel cell stacks, batteries, mobile batteries, electrolyzers, water electrolyzers, and combinations thereof.

[0197] Example

[0198] Without further explanation, those skilled in the art should be able to make full use of the invention based on the foregoing description. Therefore, the following embodiments should be understood as illustrative only and not as limiting the disclosure in any way. The starting materials of the following embodiments may not necessarily be prepared by running the specific preparation described in other embodiments. It should also be understood that any numerical ranges described herein include all values ​​from the lower limit to the upper limit. For example, if a range is stated as 10-50, values ​​such as 12-30, 20-40, or 30-50 are intended to be explicitly listed in this specification. These are merely specific examples, and all possible combinations of values ​​between and including the listed minimum and maximum values ​​are considered to be explicitly stated in this application.

[0199] Test method - Adhesion

[0200] A custom welding system was used to demonstrate the performance of the composite material as a weldable gasket. The system used a welding rod with a contact area of ​​1.5 square inches. The material was placed under the welding rod in the orientation described below. The composite material was placed between the PFSA material and the non-porous PE substrate, such that the porous layer of the composite material was in contact with the non-porous substrate, and the PFSA surface of the composite material was in contact with the PFSA material. A protective ePTFE sheet was used to separate the PFSA surface from the welding rod. The material was pressed at 120 kPa and 180°C for 2 minutes. The samples were cut into 1-inch strips using a Thwing-Albert precision sample cutter. Prior to testing, the thickness of the welded area of ​​each strip was measured using a Mituoyo falling weight thickness gauge. Three points were measured on the welded area. The average value was taken and recorded in Instron software.

[0201] Before testing, calibrate the Instron load cell. Balance the force and displacement before loading the sample. Set the gauge length to 2 inches. The method used for testing is ASTM D882 for thin plastic films. Place the sample in the jaws using tweezers and secure it with a pneumatic clamp at 40 psi. Adjust as needed to ensure the sample is flat and centered on the clamping surfaces. Once secured, test at a strain rate of 500 mm / min until the sample breaks. After testing, remove the sample and reset the crosshead to the 2-inch gauge length. Rebalance the instrument before repeating the procedure for additional samples.

[0202] Example 1. Composite Material

[0203] In this exemplary embodiment, a composite material according to the present disclosure is shown.

[0204] The composite material according to this disclosure is prepared by applying Nafion coating using a slot die coater. ™ (PFSA polymer) A polymer dispersion (10% by weight water / alcohol mixture, 1000 EW) was coated onto a porous PE substrate filled with silica particles. The coated substrate was dried at 120°C for 4 minutes. The nominal thickness of the porous PE was 160 μm. After drying, Nafion... ™ The nominal thickness of the polymer layer is 10 μm. During the coating process, Nafion... ™ The polymer partially permeates the pores of the PE substrate to form Nafion. ™ The region of mechanical entanglement between the polymer and the PE substrate. This mechanical entanglement provides good adhesion to form the composite material. The composite material includes a first layer of Nafion. ™ The Nafion consists of a polymer, a second layer of PE, and a third layer of mechanical entanglement separating the first and second layers. ™ Polymer and PE layer.

[0205] Example 2. Composite materials

[0206] In this exemplary embodiment, a composite material according to the present disclosure is shown.

[0207] The composite material according to this disclosure was prepared according to the method described in Example 1, except that the PE layer was replaced with Celgard 5550. Celgard 5550 is a 25 μm monolayer microporous PP laminated onto a PP nonwoven fabric. The nonwoven side was coated using a doctor blade coater with Nafion. ™ (PFSA polymer) Polymer dispersion (10% by weight water / alcohol mixture, EW1000) coating. During the coating process, Nafion... ™ The polymer partially permeates the pores of the PP substrate to form Nafion. ™ The region of mechanical entanglement between the polymer and the PP substrate. This mechanical entanglement provides good adhesion to form the composite material. The composite material includes a first layer of Nafion. ™ The Nafion is a polymer, a second layer of PP, and a third layer of mechanical entanglement that separates the first and second layers. ™ Polymer and PP layer.

[0208] Example 3. Composite materials

[0209] In this exemplary embodiment, a composite material according to the present disclosure is shown.

[0210] The composite material of the present invention was prepared according to the method of Example 1, except that the PE layer was replaced with Celgard 3420 and a doctor blade coater was used instead of a slot die. Celgard 3420 is a single-layer nonwoven PP separator. The nonwoven PP separator substrate was wetted by immersion in water, and then coated using a doctor blade coater with Nafion. ™ (PFSA polymer) Polymer dispersion (10% by weight water / alcohol mixture, EW 1000) is coated. During the coating process, Nafion... ™ The polymer partially permeates the pores of the PP substrate to form Nafion. ™ The region of mechanical entanglement between the polymer and the PP substrate. This mechanical entanglement provides good adhesion to form the composite material. The composite material includes a first layer of Nafion. ™ The Nafion is a polymer, a second layer of PP, and a third layer of mechanical entanglement that separates the first and second layers. ™ Polymer and PP layer.

[0211] Example 4. Composite materials

[0212] In this exemplary embodiment, a composite material according to the present disclosure is shown.

[0213] The composite material of the present invention was prepared according to the method of Example 1, except that the PE layer was replaced with a Cobetter PH1DT porous separator, and a doctor blade coater was used instead of a slit die. Cobetter PH1DT is a double-layer separator comprising an ePTFE layer supported on a nonwoven PP layer. During the coating process, Nafion... ™ The polymer partially permeates the pores on the surface of ePTFE to form Nafion. ™ The region of mechanical entanglement between the polymer and Cobetter PH1DT. This mechanical entanglement provides good adhesion to form the composite material. The composite material includes a first layer of Nafion. ™ The Nafion consists of a polymer, a second layer of ePTFE, and a third layer of mechanical entanglement separating the first and second layers. ™ The composite material includes a polymer and an ePTFE layer. It also includes a fourth layer of nonwoven PP with attached ePTFE.

[0214] Example 5. Connecting Surface

[0215] In this exemplary embodiment, it is demonstrated that the composite material according to the present disclosure can be used to bond surfaces including incompatible polymers and / or other incompatible materials.

[0216] Using the composite material from Example 1, Nafion ™ The N115 (PFSA polymer) film substrate is bonded to a non-porous PE substrate. In the tests of this invention, the composite material of Example 1 was placed between the PFSA substrate and the non-porous PE substrate, such that the porous PE layer of the composite material is in contact with the non-porous PE substrate, and the PFSA surface of the composite material is in contact with the PFSA substrate. Very strong adhesion was observed after pressing at 120 kPa (solder contact area of ​​0.375 square inches) and 180°C for 2 minutes.

[0217] The bond strength between the substrates in this embodiment of the invention was measured using a tensile testing machine. Surprisingly, the PE / PFSA strips joined by the composite material were pulled apart from the ends of the substrates under a maximum tensile stress of 25.6 ± 0.6 MPa. The tensile strength of the PFSA itself was 27.9 ± 1.1 MPa. Although the composite material was expected to exhibit extremely weak tensile strength compared to conventional welding techniques, its performance was unexpectedly close to that of the PFSA itself. The data show that the composite material enables complete bonding of two incompatible polymer surfaces and provides enhanced adhesive force.

[0218] Example 6. Connecting Surface

[0219] In this exemplary embodiment, it is demonstrated that the composite material according to the present disclosure can be used to bond surfaces including incompatible polymers and / or other incompatible materials.

[0220] According to the method described in Example 5, the composite materials of Examples 2-4 are each used to apply Nafion ™ The N115 (PFSA polymer) membrane substrate is bonded to a non-porous PE substrate.

[0221] After being pressed for 2 minutes at 120 kPa (with a solder joint contact area of ​​0.375 square inches) and 180°C, very strong adhesion was observed in each of the composite materials of Examples 2-4. Furthermore, the bond strength between the substrates in the embodiments of the invention was measured using a tensile tester. Surprisingly, it was found that the PE / PFSA strips joined by the composite material were pulled apart from the ends of the substrates at tensile strengths approaching those of the PFSA itself. The data show that the composite material is capable of fully bonding two incompatible polymer surfaces and providing enhanced adhesion.

[0222] Comparative Example 1. Connecting Surface

[0223] In this comparative example, it was demonstrated that surfaces including incompatible polymers and / or other incompatible materials cannot bond without composite materials according to this disclosure.

[0224] In the first control test, no adhesive force was generated when only PFSA and non-porous PE substrates were pressed at 120 kPa (solder contact area of ​​0.375 square inches) and 180°C for 2 minutes.

[0225] Comparative Example 2. Connecting Surface

[0226] In this comparative example, it was demonstrated that surfaces including incompatible polymers and / or other incompatible materials cannot bond without composite materials according to this disclosure.

[0227] In the second control test, no adhesive force was generated when only PFSA and porous PE substrates were pressed at 120 kPa (solder contact area of ​​0.375 square inches) and 180°C for 2 minutes.

[0228] Example 7. Weldable gasket.

[0229] In this exemplary embodiment, it is demonstrated that the composite material according to this disclosure can be used as a weldable gasket.

[0230] The composite material of Example 1 was used as a weldable gasket to seal a half-membrane electrode assembly (MEA), wherein the weldable gasket was applied only to one side of the membrane. The MEA was made of a 15 μm thick PFSA membrane. The weldable gasket according to Example 1 was arranged on one side of the membrane to cover only the periphery of the membrane, wherein the polymer electrolyte surface of the weldable gasket contacted the edge of the membrane. The gasket and membrane were simultaneously hot-pressed between 8" × 8" steel plates at 140°C for 7 minutes. The force was 3000 psi. The pressure was maintained until the plate temperature dropped below 40°C. This produced a welded MEA.

[0231] The test unit is designed to apply stress to the sealing area between the test gasket and the membrane. A second gasket is placed against the test assembly made of the test gasket, such that the membrane does not contact the second gasket. The test design does not provide any support at the joint between the test gasket and the membrane.

[0232] Place the test assembly between two plates with flow channels. At ambient temperature, allow 1 standard liter / minute of dry nitrogen to flow into one half of the cell for 3 minutes. Observe the outlet of the other half of the cell for leaks. If no bubbles are observed or very few bubbles are observed, increase the pressure of the nitrogen flowing into the cell and repeat the 3-minute pressure holding test.

[0233] No gas flow or bubbling was observed in the test component below 150 kPa. Between 150 kPa and 200 kPa, slow bubbling was observed, with one bubble generated every 10–15 seconds. Between 250 kPa and 300 kPa, moderate bubbling was observed, with one bubble generated every 5–10 seconds. At 345 kPa, moderate bubbling was observed, with one bubble generated every 3–5 seconds.

[0234] Comparative Example 3. Weldable gasket.

[0235] In this comparative example, it was demonstrated that composite materials not according to this disclosure cannot be used as weldable washers.

[0236] A control MEA was also prepared using a method similar to that of Example 5, except that a standard gasket material (polyethylene) was used instead of a weldable gasket. The PE gasket was used as the gasket for sealing the half-membrane electrode assembly (MEA), wherein the PE gasket was applied only to one side of the membrane. The MEA was made of a 15 μm thick PFSA membrane. The PE gasket was placed on one side of the membrane and aligned to cover only the periphery of the membrane. The PE gasket and membrane were simultaneously hot-pressed between 8" × 8" steel plates at 140°C for 7 minutes. The force was 3000 psi. The pressure was maintained until the plate temperature dropped below 40°C. This produced the comparative MEA.

[0237] Place the test assembly between two plates with flow channels. At ambient temperature, allow 1 standard liter / minute of dry nitrogen to flow into one half of the cell for 3 minutes. Observe the outlet of the other half of the cell for leaks. If no bubbles are observed or very few bubbles are observed, increase the pressure of the nitrogen flowing into the cell and repeat the 3-minute pressure holding test.

[0238] The test assembly prepared with the control gasket showed visible bubbles flowing from the battery into the water trap. Rapid bubbling was observed, with one bubble generated every less than 1 second.

[0239] Example 8. Composite materials

[0240] Repeat Example 4, using Cobetter P04HZ instead of Cobetter PH1DT.

[0241] Example 9. Connecting Surface

[0242] Repeat Example 6, using the composite material from Example 2 to bond PFSA to nonporous polypropylene.

[0243] Example 10. Connecting Surface

[0244] Repeat Example 6, using the composite material from Example 3 to bond PFSA to nonporous polypropylene.

[0245] Example 11. Connecting Surface

[0246] Example 6 was repeated, using the composite material from Example 4 to bond PFSA to nonporous polypropylene.

[0247] Example 12. Connecting Surface

[0248] Repeat Example 6, using the composite material from Example 8 to bond PFSA to nonporous polypropylene.

[0249] Comparative Example 4

[0250] Example 5 was repeated, but a porous PE substrate filled with silica particles between the PFSA and the non-porous PE layer was used instead of the composite material interface.

[0251] Comparative Example 5

[0252] Repeat Example 9, using Celgard 5550 instead of the composite interface between the PFSA and the non-porous polypropylene layer.

[0253] Comparative Example 6

[0254] Repeat Example 10, using Celgard 3420 instead of the composite interface between the PFSA and the non-porous polypropylene layer.

[0255] Comparative Example 7

[0256] Example 12 was repeated, with Cobetter P04HZ used instead of the composite interface between the PFSA and the non-porous polypropylene layer.

[0257] Table 1. Adhesive force of the joint surfaces

[0258] in conclusion

[0259] Surprisingly, this disclosure reveals that composite materials comprising incompatible polymers and / or other incompatible materials can be produced by joining the incompatible polymers and / or other incompatible materials to an interface comprising one material contained in a fluid-permeable portion of another material. Such composite materials unexpectedly exhibit improved tensile strength and adhesive force. They can be used in a variety of applications requiring the joining of incompatible polymers and / or other incompatible materials. They are particularly suitable for applications requiring the joining of incompatible polymers and for applications subject to prolonged exposure to elevated temperatures and / or elevated pressures.

[0260] This specification uses examples to illustrate this disclosure, including the best practices, and also enables any person skilled in the art to practice this disclosure, including preparing and using any composition or system and implementing any incorporated methods. The patentable scope of this disclosure is defined by the claims, but may include other examples that would occur to a person skilled in the art. Such other examples are intended to fall within the scope of the claims if they have elements that do not differ from the literal language of the claims, or if they include equivalent elements that do not substantially differ from the literal language of the claims.

[0261] As used herein, the terms “comprising,” “including,” “having,” “containing,” “characterized in,” or any other variations thereof are intended to cover non-exclusive inclusion, but are subject to any expressly indicated limitation. For example, a composition, mixture, process, or method that includes a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed or inherent to such composition, mixture, process, or method.

[0262] The transitional phrase "composed of..." does not include any unspecified elements, steps, or components. If in a claim, it will not include protection for materials other than those described, except for impurities typically associated with them. When the phrase "composed of..." appears in a clause of the body of a claim, rather than immediately following the preamble, it only limits the elements set forth in that clause; other elements as a whole are not excluded from the claim.

[0263] The transitional phrase "consistently of..." is used to define a composition or method that includes, in addition to the literally disclosed materials, steps, features, components, or elements, other materials, steps, features, components, or elements, provided that such additionally included materials, steps, features, components, or elements do not materially affect the essential and novel characteristics of the invention protected by the claims. The term "consistently of..." falls between "comprising" and "consisting of...".

[0264] Where the invention or a portion thereof has been defined using open-ended terms such as “comprising”, it should be readily understood (unless otherwise stated) that the specification should be interpreted as also using the terms “substantially consisting of” or “consisting of” to describe such inventions.

[0265] Furthermore, unless explicitly stated otherwise, "or" refers to an inclusive "or" and is not an exclusive "or". For example, conditions A or B satisfy one of the following: A is true (or exists) and B is false (or does not exist), A is false (or does not exist) and B is true (or exists), and both A and B are true (or exist).

[0266] Furthermore, the indefinite articles “a” and “an” preceding the elements or components of the invention are intended to be non-limiting in relation to the number of instances (i.e., the occurrence of the element or component). Thus, “a” or “an” should be understood to include one or at least one, and the singular form of an element or component also includes the plural, unless the number is obviously singular.

[0267] As used in this article, the term “about” means plus or minus 10% of the value.

Claims

1. A composite material, said composite material comprising: The first component includes a first material having a fluid-permeable portion; and The second component includes a second material that is incompatible with the first material; The first component and the second component are connected at an interface, the interface including the second material contained in the fluid-permeable portion of the first material; and The interface forms a third component that separates at least a portion of the first component from the second component.

2. The composite material according to claim 1, wherein the first material is selected from porous polymer materials, polyolefins, aromatic hydrocarbon polymers, polyethylene (PE), polypropylene (PP), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), polyvinyl chloride (PVC), polysulfone, polyethersulfone, polyphenylene sulfone, polyphenylene sulfide (PPS), poly(aryl ether sulfone), polystyrene, polyethylene oxide, copolymers thereof, hydrophilic treatments thereof, mixtures thereof, and combinations thereof.

3. The composite material according to claim 1, wherein the fluid-permeable portion is selected from pores, grooves, ridges, pits, indentations, holes, through holes, and combinations thereof.

4. The composite material according to claim 1, wherein the second material is selected from hydrocarbon polymer electrolytes, partially fluorinated polymer electrolytes, fluorinated polymer electrolytes, ionomers, cation exchange polymers, anion exchange polymers, sulfonated tetrafluoroethylene polymers, sulfonated tetrafluoroethylene vinyl fluoropolymer copolymers, perfluorosulfonic acid (PFSA) polymers, copolymers thereof, their sulfonates, and combinations thereof.

5. The composite material according to claim 1, wherein the interface is formed by a method comprising: Receives a liquid component comprising the second material and a liquid carrier in the fluid-permeable portion of the first material; and The liquid component is solidified in the fluid-permeable portion of the first material.

6. The composite material according to claim 1, wherein the composite material is selected from membranes, strips, welding strips, welding media, sheets, blocks, rods, tubes, and combinations thereof.

7. The composite material according to claim 1, wherein the first component and the second component are mechanically interlocked at the interface.

8. A product comprising the composite material of claim 1, wherein the composite material comprises a first surface of a material compatible with the first material and a second surface comprising a material compatible with the second material.

9. The product of claim 8, wherein the product is configured to be used for an extended period of time under elevated pressure and / or temperature.

10. The product of claim 8, wherein the first surface and / or the second surface are each selected from the surface of a membrane, the surface of a diaphragm, the surface of a separator, the surface of a fuel cell, the surface of a fuel cell stack, the surface of a battery, the surface of a flow battery, the surface of an electrolyzer, the surface of a water electrolyzer, the surface of an electrode, the surface of a cathode, the surface of an anode, the surface of a membrane electrode assembly, the surface of a catalyst, the surface of a flow field plate, the surface of a gasket, the surface of a sealing gasket, the surface of a membrane, the surface of a gas diffusion substrate, the surface of a gas diffusion electrode, the surface of a porous transport layer, a catalyst-coated membrane, and combinations thereof.

11. The product of claim 10, wherein the membrane, diaphragm, and separator further comprise a reinforcing material.

12. The product of claim 11, wherein the reinforcing material is PTFE, ePTFE, PEEK, PES, PE, PP, PPS, or a combination thereof.

13. The product of claim 8, wherein the product is selected from the surface of a membrane, the surface of a diaphragm, the surface of a separator, the surface of a fuel cell, the surface of a fuel cell stack, the surface of a battery, the surface of a flow battery, the surface of an electrolyzer, the surface of a water electrolyzer, the surface of an electrode, the surface of a cathode, the surface of an anode, the surface of a membrane electrode assembly, the surface of a catalyst, the surface of a flow field plate, the surface of a gasket, the surface of a sealing gasket, the surface of a gas diffusion substrate, the surface of a gas diffusion electrode, the surface of a porous transport layer, a catalyst-coated membrane, and combinations thereof.

14. A membrane electrode assembly (MEA) comprising the composite material according to claim 1.

15. A method for preparing a composite material, the composite material comprising: The first component includes a first material having a fluid-permeable portion; and The second component includes a second material that is incompatible with the first material; The first component and the second component are connected at an interface, the interface including the second material contained in the fluid-permeable portion of the first material; and The interface forms a third component that separates at least a portion of the first component from the second component, and the method includes: A liquid component comprising the second material and a liquid carrier is received in the fluid-permeable portion of the first material; as well as The liquid component is solidified in the fluid-permeable portion of the first material.

16. The method of claim 15, wherein when the liquid component is applied using a technique selected from: coating, slot die coating, doctor blade coating, bar coating, Mayer bar coating, gravure coating, electrophoretic coating, impregnation, spraying, and combinations thereof.

17. The method of claim 15, wherein the liquid component is received in the fluid-permeable portion of the first material at a temperature below about 50°C.

18. The method of claim 15, wherein curing the liquid component in the fluid-permeable portion of the first material comprises drying the liquid component.

19. A method of using a composite material, the composite material comprising: The first component includes a first material having a fluid-permeable portion; and The second component includes a second material that is incompatible with the first material; The first component and the second component are connected at an interface, the interface including the second material contained in the fluid-permeable portion of the first material; and The interface forms a third component that separates at least a portion of the first component from the second component, and the method includes: The composite material is used to join a first surface comprising a material compatible with the first material and a second surface comprising a material compatible with the second material.

20. The method of claim 19, wherein the first surface and / or the second surface are each selected from the surface of a membrane, the surface of a diaphragm, the surface of a separator, the surface of a fuel cell, the surface of a fuel cell stack, the surface of a battery, the surface of a flow battery, the surface of an electrolyzer, the surface of a water electrolyzer, the surface of an electrode, the surface of a cathode, the surface of an anode, the surface of a membrane electrode assembly, the surface of a catalyst, the surface of a flow field plate, the surface of a gasket, the surface of a sealing gasket, the surface of a membrane, the surface of a gas diffusion substrate, the surface of a gas diffusion electrode, the surface of a porous transport layer, a catalyst-coated membrane, and combinations thereof.

21. The product of claim 20, wherein the membrane, diaphragm, and separator further comprise a reinforcing material.

22. The product of claim 21, wherein the reinforcing material is PTFE, ePTFE, PEEK, PES, PE, PP, PPS, or a combination thereof.

23. The method of claim 19, wherein each of the first surface and the second surface is joined to the composite material using a welding technique selected from ultrasonic welding, hot gas welding, high-speed tip welding, injection welding, vibration welding, laser welding, rotary welding, infrared welding, induction welding, high-frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

24. A membrane electrode assembly (MEA), the membrane electrode assembly comprising: membrane; At least one electrocatalyst layer is disposed on one side of the membrane; Optionally, at least one gas diffusion substrate and / or porous transport layer in physical contact with the at least one electrocatalyst layer; and Composite material, the composite material comprising: A first component, the first component comprising a first material having a fluid-permeable portion; and The second component includes a second material that is incompatible with the first material; The first component and the second component are joined at an interface, the interface comprising the second material contained within the fluid-permeable portion of the first material; and The interface forms a third component that separates at least a portion of the first component from the second component; The composite material is bonded to a first surface comprising a material compatible with the first material and / or a second surface comprising a material compatible with the second material; and The first surface and / or the second surface are each selected from the surface of the membrane, the surface of the gasket, the surface of the sealing gasket, the surface of the at least one electrocatalyst layer, the surface of the electrolyzer, the surface of the at least one gas diffusion substrate and / or porous transport layer, and combinations thereof.

25. The MEA of claim 24, wherein the first surface and / or the second surface are respectively joined to the composite material using welding techniques selected from ultrasonic welding, hot gas welding, high-speed tip welding, injection welding, vibration welding, laser welding, rotary welding, infrared welding, induction welding, high-frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

26. The MEA of claim 24, wherein the at least one electrocatalyst layer comprises two electrocatalyst layers disposed on different sides of the membrane.

27. The MEA of claim 24, wherein the at least one gas diffusion substrate comprises two gas diffusion substrates, wherein the two gas diffusion substrates are in physical contact with different electrocatalyst layers.

28. The MEA of claim 24, wherein the composite material is in edge contact with each of the two electrocatalyst layers and / or at least one gas diffusion substrate and / or porous transport layer.

29. A component, the component comprising: At least one sealing gasket, the at least one sealing gasket including a first surface and / or a second surface, the first surface including a material compatible with the first material, and the second surface including a material compatible with the second material; and According to claim 24, The composite material is coupled to the first surface of the at least one sealing gasket and / or the second surface of the at least one sealing gasket.

30. The component of claim 29, wherein the first surface of the at least one sealing gasket and / or the second surface of the at least one sealing gasket are respectively joined to the composite material using welding technology, the welding technology being selected from ultrasonic welding, hot gas welding, high-speed tip welding, injection welding, vibration welding, laser welding, rotary welding, infrared welding, induction welding, high-frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

31. The component of claim 29, the component comprising at least two sealing gaskets, wherein each of the at least two sealing gaskets is coupled to the composite material.

32. The component of claim 29, wherein the component is a sealing component.

33. A product comprising the components according to claim 29.

34. The product of claim 33, wherein the product is configured to be used for an extended period of time under elevated pressure and / or temperature.

35. The product of claim 33, wherein the product is selected from fuel cell stacks, fuel cells, fuel cell stacks, batteries, mobile batteries, electrolyzers, water electrolyzers, and combinations thereof.

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